Wall construction



April 5, 1955 G. E. ROSE WALL CONSTRUCTION 2 Sheets-Sheet 1 Filed March 16, 1949 HTrol? April 5, 1955 Filed March 16, 1949 G. E. ROSE 2,705,414

WALL CONSTRUCTION 2 Sheets-Sheet 2 United States Patent WALL CONSTRUCTION George E. Rose, Florissant, Mo., assignor to Laclede- Christy Company, St. Louis, Mo., a corporation of Missouri Application March 16, 1949, Serial No. 81,827 3 Claims. (Cl. 72-14) The present invention relates generally to fabricated constructions, and more particularly to a fabricated supported wall and to the component parts thereof.

In the oil industry, a number of processes are used in refining the oil, as is well known, and, in the so-called continuous process, among others, regenerative kiln for reclaiming pellet type catalysts for further use in the process. The kiln may be of cylindrical form of eleven to twelve feet internal diameter and of seventy feet in height, the supported inner wall of which is subjected to abrasion inasmuch as the pellets are introduced into the kiln by an air blast and are moved thereby through the kiln in a directed path determined by internal well known details of the kiln.

Further, there is often a pulsating pressure in the kiln caused by a number of factors which causes failure in the walls of regenerative kilns presently being used. Such wall failure under pulsating pressure is often attributed to what may be termed lost motion accumulation in respect to the component parts of the presently used kilns.

Difiiculties of construction and repair are also inherent in kilns now in use.

Therefore, an object of the present invention is to provide a novel supported wall construction for regenerative kilns or the like which overcomes the manifold objections existing in the walls of present day regenerative kilns and the like.

Another object is to provide a novel supported wall construction which incorporates but a single movable contact between the interior lining and the outer shell which reduces to a minimum wall failure due to pulsating pressures or the like.

Another object is to provide a novel supported wall construction which incorporates a plurality of studs welded to the inner surface of the outer casing in a predetermined spaced design which are, in effect, integral parts of the outer casing, and which lend support to preformed blocks or tiles interlocked to form the lining of the wall construction.

Another object is to provide a novel method of constructing a supported wall construction by which the actual formation of the wall construction is simplified and made effective against lining failure and through which repair of a lining section may be effected without destruction of the whole lining.

Another object is to provide a novel tile for formation of a supported lining which incorporates stud head and shank receiving means, and opposed tongue and groove formations for interlocking relationship.

Another object is to provide a novel supported Wall construction which incorporates a metal outer shell to the inner surface of which are welded spaced studs, and interlocking tiles every two of which are supported by a stud for weight distribution and for removal of tiles in the repair of a section of the kiln.

Another object is to provide a novel supported wall construction which incorporates high heat resistant studs welded to the outer casing so that the studs conduct to the shell for dissipation a sufficient amount of heat to which they are subjected to prevent softening thereof and subsequent sag.

Another object is to provide a wall construction incorporating novel insulation installation and a method of forming the same.

Other objects are to provide a supported wall construction for regenerative kilns, stacks, or the like, which may be readily fabricated, which is resistant to damage there is employed a from pulsating pressures, abrasion, and other destructive factors, and which lends itself to wide adaptation.

The foregoing and other objects and advantages are apparent from the following description taken with the accompanying drawings, in which:

Fig. 1 is an elevational view of a fragment of a cylindrical regenerative kiln constructed in accordance with the teachings of the present invention;

Fig. 2 is an enlarged fragmentary vertical radial crossi ectiolnal view taken on substantially the line 2--2 of Fig. 3 is a further enlarged fragmentary view of the inner face of the wall lining, portions being broken away and being in section to illustrate structural details;

Fig. 4 is a fragmentary radial vertical cross-sectional view taken on substantially the line: 2--2 of Fig. 1 on the same scale as Fig. 3;

Fig. 5 is a top plan view of a tile incorporating the teachings of the present invention;

Fig. 6 is a bottom view thereof;

Fig. 7 is a rear elevational view thereof;

Fig. 8 is an end elevational view .looking towards the left end when considering Fig. 5;

Fig. 9 is an end elevational view, a portion being broken away and in section to illustrate the stud receiving recfss, looking towards the right in considering Fig. 5 an Fig. 10 is an isometric view of a tile supporting stud.

Referring to the drawings more particularly by reference numerals, 14 indicates generally a supported wall construction which defines a regenerative kiln 16 of any desired diameter or width and height. The wall construction 14 broadly includes an outer metal shell 18, spaced studs 20 welded thereto, preformed refractory tiles or blocks 22 supported by the studs 20 and forming a lining 23, and suitable insulation 24.

The metal casing 18 is usually formed of riveted or welded sections, the illustrated casing 18 being of cylindrical form. The studs 20 are preferably Nelson high temperature stainless steel precharged studs including a shank 26 and a head 23 which are welded to the easing 18 on radial lines and in a predetermined pattern for subsequent supporting reception of the tiles 22. The studs 20 are Welded to the casing 18 by Nelson welding guns or the like, both the studs 20 and the equipment for applying the same being commercially used and patented products which may be purchased on the open market. The studs become, in effect, through the welding operation integral parts of the casing 18 and readily dissipate through the casing 18 excessive heat to which they may be subjected, thereby reducing to a minimum the possibility of softening under excessive heat which would manifestly result in bending of the particular overheated stud or studs with subsequent wall damage.

The tiles 22 are precast of an abrasion resisting mix, being designed to resist the abrasive effects of the pellet catalysts regenerated in the kiln 16. A preferred form of tile 22 is illustrated in Figs. 5 through 9. The tile 22 includes arcuate front and rear surfaces 30 and 32, the degree of curvature manifestly being determined by the radius of the kiln 16 or other structure. Oblong tiles of similar configuration, save for the arcuateness, may be provided. The tile 22 also includes a top surface 34, a bottom surface 36, and end surfaces 38 and 40, the latter two surfaces being formed on converging radii corresponding to the radius of the kiln 16. A groove 42 is formed in the top surface 34 and a corresponding tongue 44 extends outwardly from the bottom surface 36. Similarly, a groove 46 is formed in the end surface 38 and a tongue 48 extends outwardly from the end surface 40. Full notches or corner cutaways 50 and 52 are formed in the end surfaces 38 and 40, .respectively, which open into the rear surface 32. Extending inwardly from the bottom surface 36 is a rectangular well 54. A shallow channel 56 is formed in the bottom surface 36 adjacent the well 54 and communicates it with the rear surface 32.

In fabricating the kiln 16, the casing 18 is formed and the studs 20 are welded to the interior surface thereof in a predetermined pattern. The studs may be welded to plates or sections in the same predetermined pattern prior to welding together of such plates or sections in the formation of the shell 18. The spacing of the studs is determined by the configuration of the tiles 22, it being desired in general to provide a stud 20 to support each tile 22 of the base tier of each bay or section and a stud 20 to support each tile 22 of every other tier above such base tier. This pattern is clearly illustrated in the draw- II! s.

After the stud pattern is completed, the tiles 22 are readily formed into the lining 23 of the kiln 16, the bottom tier resting upon a suitable foundation which may be a row of studs 20. Tiers of tiles 22 are stacked on the base tier staggered as shown, the lining 23 being formed in vertical sections or bays. Each tile 22 of a base tier of a section or bay receives the head 28 of a stud 20 in its well 54. The second tier of tiles 22 is stacked on the base tier in tongue and groove interlocking relation with the notches 50 and 52 of each tile 22 engaging the lower quarters of the heads of the two closest studs of the next upper row. The third tier of tiles 22 has each tile 22 supported by a stud 20, and so forth. Preferably, as is shown in Fig. 3, the upper tier of each bay is stud supported which results in a desired staggering of the vertically spaced studs 20 of each bay. Hence, in effect the weight of every two tiles 22 is supported by a stud 20, thereby distributing the weight of the lining 23. The tongue and groove arrangement of the tiles 22 insures a rigid vertical pile relationship between the several tiles 22 forming the lining 23 and assists in resisting wall damage from pulsating pressures or other interior forces.

The lining 23 of the wall construction 14 is preferably formed as stated in vertical bays separated by circular joints 58 formed of suitable heat and abrasive resistant mortar material. The thickness of the joint 58 may be around one-half inch which will permit a tile 22 therebeneath to be raised and removed from its supporting stud 20 upon removal of the mortar forming the joint 58. Hence, damaged sections of the lining 23 may be removed for replacement Without its total destruction. The number of tiers of tiles 22 per bay is manifestly a matter of construction choice.

The insulation 24 in a preferred installation comprises blocks 25 of a compressible insulating material of a width substantially half the horizontal centerline distance between two studs, of a selected thickness such as three inches, and of a vertical depth of a selected multiple of the vertical depth of the tiles 22 such as twenty-four inches. The blocks 25 are installed before the tiles 22 are stacked, two blocks 25 being put in position at a time. Two blocks 25 are placed against opposed studs 20 and at an angle to each other with adjacent inner edges in contact. The two blocks 25 are then forced inwardly simultaneously against the shell 18 to bring the adjacent ends in substantiailly parallel relation, whereupon the insulation material will compress along the lines of the engaged studs 20, so that the blocks 25 will be retained in position by said studs 20 and each will fill half the vertical areas between studs 20 at its free end which otherwise would be without insulation were the block 25 to merely abut the studs 20. Adjacent blocks 25 will fill the other halves of the vertical areas between studs 20 as a tier of insulation is formed.

It is clear from the foregoing, taken with the drawings, that the only movable connection in the wall construction 14 is that of the individual supporting relationship of the tiles 22 and the studs 20 which is only a sliding one and one involving a minimum amount of movement consistent with expansion and contraction. Hence, the several connections found in present day constructions employed for the same purposes as the wall construction 14 are eliminated, thereby eliminating the lining failures which result from accumulation of lost motion connections. Furthermore, the weight of the lining 23 is evenly distributed in the present wall construction 14.

It is to be observed that each stud supported tile 22 rests upon the shank 26 of the supporting stud 20 and not upon the head 28, the last-named maintaining the tile 22 against inward and outward movement at its base.

The present invention is shown embodied in a kiln construction, but it manifestly may be adapted to stacks and other constructions.

It is manifest that there has been provided a novel wall construction and a method of forming the same, together with novel components including the tile 0f the lining, the insulation, and the method of installing the insulation tile which fulfill the objects and advantages sought therefor.

It is to be understood that the foregoing description and the accompanying drawings have been given by Way of illustration and example. It is also to be understood that changes in form of the several parts, substitution of equivalent elements or steps, and rearrangement of parts or steps, which will be readily apparent to one skilled in the art, are contemplated as within the scope of the present invention, which is limited only by the claims which follow.

What is claimed is:

1. In a regenerative kiln, in combination, an outer cylindrical metal casing of predetermined height, headed studs welded to the inner surface of said casing and extending substantially radially inwardly, and a cylindrical lining spaced inwardly of said casing and supported on said studs, said lining comprising tiers of identical individual refractory tiles, the tiles of each tier being staggered with the tiles of the tiers above and below the same, each refractory tile being of arcuate form and of substantially rectangular cross section and including a well in the bottom between the ends thereof for freely receiving a stud head and a channel leading from the well rearwardly for supportingly receiving a stud shank, each refractory tile of the bottom tier, the top tier, and only alternate tiers therebetween being individually freely supported on the shank of a stud permitting only slight relative movement therebetween, said free connections between studs and refractory tiles comprising the only connections between said lining and said casing, each refractory tile also including vertical rear corner notches, the rear corner notches of endwise abutting refractory tiles in tiers other than said bottom, top, and alternate tiers freely receiving the lower portion of the head of a stud supporting a superposed refractory tile.

2. In a regenerative kiln, in combination, an outer cylindrical metal casing of predetermined height, headed studs welded to the inner surface of said casing and extending substantially radially inwardly, and a cylindrical lining spaced inwardly of said casing and supported on said studs, said lining comprising tiers of identical individual refractory tiles, the tiles of each tier being staggered with the tiles of the tiers above and below the same, each refractory tile being of arcuate form and of substantially rectangular cross section and including a well in the bottom between the ends thereof for freely receiving a stud head and a channel leading from the well rearwardly for supportingly receiving a stud shank, said channel and well being of widths predeterminately greater than the diameter of said stud shank and width of said stud head received therein, respectively, each refractory tile of the bottom tier, the top tier, and only alternate tiers therebetween being individually freely supported on the shank of a stud permitting only slight relative movement therebetween, said free connections between studs and refractory tiles comprising the only connections between said lining and said casing, each refractory tile also including vertical rear corner notches, the rear corner notches of endwise abutting refractory tiles in tiers other than said bottom, top, and alternate tiers freely receiving the lower portion of the head of a stud supporting a superposed refractory tile.

3. In a regenerative kiln, in combination an outer cylindrical metal casing of predetermined height, headed studs welded to the inner surface of said casing and extending substantially radially inwardly, said studs being of high temperature steel and adapted through said welding connection with said casing to dissipate heat through said casing, and a cylindrical lining spaced inwardly of said casing and supported on said studs, said lining comprising tiers of identical individual refractory tiles, the tiles of each tier being staggered with the tiles of the tiers above and below the same, each refractory tile being of arcuate form and of substantially rectangular cross section and including a well in the bottom between the ends thereof for freely receiving a stud head and a channel leading from the well rearwardly for supportingly receiving a stud shank, each refractory tile of the bottom tier, the top tier, and only alternate tiers therebetween being individually freely supported on the shank of a stud permittmg only slight relative movement therebetween, said free connections between studs and refractory tiles comprising the only connections between said lining and said casing, each refractory tile also including vertical rear corner notches, the rear corner notches of endwise abutting refractory tiles in tiers other than said bottom, top, and alternate tiers freely receiving the lower portion of the head of a stud supporting a superposed refractory ti c.

References Cited in the file of this patent UNITED STATES PATENTS 373,703

Wagg Nov. 22, 1887 10 6 Tanner Dec. 21, Kohler June 7, Christenson May 5, Hosbein July 6, Young Feb. 6, Gambo Aug. 14, Werner Jan. 25, Weber Jan. 8, Sampson Apr. 8, 

